An anodic carbon block production line control system and method

Abstract

The present invention relates to the technical field of carbon block production control, and discloses a control system and method for an anode carbon block production line. The system includes a contact area measurement module, a voltage drop detection module, a surface treatment module, a conductive material filling module, and a dynamic adjustment module. The system first measures the initial contact area and voltage drop between iron and the carbon block, and then calculates the theoretical maximum contact area according to the contact situation. By optimizing the contact surface through mechanical grinding, polishing, and filling graphite powder, etc., the contact area can be effectively increased and the voltage drop can be reduced. The optimization verification link can accurately calculate the increase and decrease ratios to ensure the optimization effect. The system has a dynamic adjustment mechanism. If the reduction ratio of the voltage drop does not meet the expectation, the contact area after adjustment can be calculated and the treatment can be increased. The sawtooth processing method is adopted to increase the contact surface, and multiple steps of operations are carried out to ensure that the increased area meets the requirements. It has strong operability, can improve the electrical conductivity of the anode carbon block production line, reduce power consumption, and ensure the stable operation of the production line.

Description

Technical Field

[0001] The present invention relates to the technical field of carbon block production control, and specifically relates to a control system and method for an anode carbon block production line. Background Art

[0002] In the fields of anode carbon block production and related industrial applications, good electrical contact between iron and carbon blocks is crucial. Anode carbon blocks are widely used in industries such as electrolytic aluminum. During the electrolysis process, the iron electrode and the anode carbon block, as key conductive components, their contact performance directly affects the power transmission efficiency and production energy consumption.

[0003] Currently, there are many problems with the traditional iron-carbon block contact method. On the one hand, the contact surface between iron and carbon blocks often has surface roughness due to factors such as processing technology, resulting in a relatively small actual effective contact area. This smaller contact area will generate a relatively large contact resistance. According to Ohm's law, the increase in contact resistance will cause a significant voltage drop. In large-scale industrial production, such as an electrolytic aluminum production line, a large amount of electrical energy is lost due to this unnecessary voltage drop, increasing production costs and reducing energy utilization efficiency.

[0004] On the other hand, the existing iron-carbon block contact structure and control method lack dynamic adaptability. During the production process, due to fluctuations in working conditions such as temperature and pressure, the contact state between iron and carbon blocks will change, and the contact resistance will also change accordingly. However, the traditional method cannot effectively adjust the contact area and pressure in real time, and it is difficult to ensure stable and efficient electrical conductivity. For example, when the environmental temperature rises and causes thermal expansion of the material, the contact pressure between iron and carbon blocks may change, thereby affecting the contact resistance, but the existing technology cannot respond in a timely manner and optimize the contact state.

[0005] In addition, the existing iron-carbon block contact surface structure is relatively simple, mostly simple planar contact. This structure is difficult to make full use of the material surface and cannot maximize the contact area. For some carbon blocks with complex shapes or special working condition requirements, the traditional planar contact structure cannot meet the requirements of high-efficiency electrical conductivity.

[0006] In summary, in the existing anode carbon block production line, the contact technology between iron and carbon blocks has deficiencies in improving electrical conductivity, adapting to changes in working conditions, and optimizing the structure. There is an urgent need for an innovative control system and method to solve these problems in order to improve the power transmission efficiency and stability of anode carbon block production and related industrial applications. Summary of the Invention

[0007] The purpose of the present invention is to provide a control system and method for an anode carbon block production line, which solves the technical problems proposed in the background art.

[0008] The purpose of the present invention can be achieved by the following technical solutions:

[0009] An anode carbon block production line control system and method, comprising the following steps:

[0010] Step 1: Measurement of initial contact area and voltage drop:

[0011] Under the initial contact state of iron and carbon block, measure the initial contact area and initial voltage drop between the two;

[0012] Step 2: Calculation of maximum contact area:

[0013] For planar contact, the theoretical maximum contact area is the surface area of the smaller one of the two;

[0014] For non-planar contact, it is calculated by the following method:

[0015] If one of the iron surface and the carbon block is planar and the other is arc-shaped, the theoretical maximum contact area is the area of the tangent contact region between the arc surface and the planar surface;

[0016] Its calculation formula is: S max =2πrh;

[0017] In the formula, S max is the theoretical maximum contact area of the iron surface and the carbon block, r is the radius of the arc surface, and h is the contact height;

[0018] Step 3: Optimization of contact surface:

[0019] Perform mechanical grinding or polishing operations on the contact surface of iron or carbon block, and fill a highly conductive material between the iron and the carbon block;

[0020] Step 4: Optimization verification:

[0021] Measure the optimized contact area and voltage drop, then calculate the contact area increase ratio and voltage drop decrease ratio. When the voltage drop decrease ratio is greater than the preset voltage drop decrease threshold, calculate the proportional adjustment coefficient between the contact area increase ratio and the voltage drop decrease ratio;

[0022] Step 5: Dynamic adjustment of contact area:

[0023] Obtain the preset target voltage drop reduction threshold γm, and then compare the voltage drop reduction ratio γ with it:

[0024] When γ≥γm, it is determined that the current optimized contact area after the contact surface optimization treatment reaches the expected effect;

[0025] When γ < γm, it is determined that the current optimized contact area after the contact surface optimization treatment has not achieved the expected effect. Subsequently, the adjusted contact area corresponding to the iron or carbon block is determined, and finally, the contact surface between the iron and the carbon block is increased based on the adjusted contact area.

[0026] As a further solution of the present invention: Among them, the measurement method of the initial contact area is as follows:

[0027] Adopt the conductive coating method, coat the conductive material on the contact surface, and calculate the contact area by measuring the conductive area;

[0028] The measurement method of the initial voltage drop is as follows:

[0029] Apply a constant current between the iron and the carbon block, and then measure the voltage difference at both ends through a voltage measuring instrument and record it as the initial voltage drop.

[0030] As a further solution of the present invention: In the contact surface optimization step:

[0031] Before performing the mechanical grinding or polishing operation, measure the initial roughness of the contact surface of the iron or carbon block with a roughness measuring instrument and record it as R0;

[0032] After performing the mechanical grinding or polishing operation, measure the processed roughness of the contact surface of the iron or carbon block with a roughness measuring instrument and mark it as R1;

[0033] Subsequently, through: , calculate the theoretical maximum contact area S1 after the flattening treatment max ;

[0034] In the formula, β is a preset material adaptation coefficient;

[0035] Then through: , calculate the theoretical maximum contact area S2 after the conductive material filling treatment max ;

[0036] In the formula, AS is the effective contact area of the high-conductivity material.

[0037] As a further solution of the present invention: Among them, the high-conductivity material is selected as graphite powder; the effective contact area of the graphite powder is obtained by measuring the thickness and area of the filling area and combining the parameters corresponding to the bulk density of the graphite powder; the specific method is as follows:

[0038] Measure the thickness of the filling area:

[0039] Use a high-precision thickness measuring instrument;

[0040] In the area filled with graphite powder, select multiple measurement points evenly distributed in the filling area for thickness measurement;

[0041] Measuring the area of the filled region:

[0042] If the filled region is a regular geometric shape, such as a rectangle, use a ruler tool to measure its length a and width b, and calculate the area S of the filled region according to the rectangle area formula S t = a×b t ;

[0043] If it is a circle, use a caliper to measure its diameter d, and calculate the area S of the filled region according to the circle area formula S t = π(d / 2) 2 to calculate the area S of the filled region t ;

[0044] Determining the bulk density of graphite powder: Determine the bulk density ρ of graphite powder by referring to relevant materials or through self-experimentation;

[0045] When conducting self-experimentation, pour a certain mass m of graphite powder into a container with a known volume V, gently vibrate it to make the graphite powder densely packed, and then calculate the bulk density of graphite powder according to the density calculation formula ρ = m / V;

[0046] Estimating the effective contact area: Assume that the graphite powder is evenly distributed within the filled region. According to the volume formula V = S t ×h p to calculate the volume filled with graphite powder;

[0047] Combined with the bulk density, estimate the mass m of graphite powder = ρ×S t ×h p ;

[0048] Determine the proportionality coefficient e between the effective contact area and the mass of graphite powder through experiments. Specifically: Measure the effective contact area of a specified mass of graphite powder under standard contact conditions to obtain this proportional relationship;

[0049] Then the effective contact area AS = e×m = e×ρ×S t ×h p .

[0050] As a further solution of the present invention: The optimization verification method is specifically as follows:

[0051] Step N1. According to the method of measuring the initial contact area and voltage drop in Step 1, measure the optimized contact area and optimized voltage drop after being processed by the above optimization method;

[0052] The measurement methods of the optimized contact area and the initial contact area are the same;

[0053] The measurement methods of the optimized voltage drop and the initial voltage drop are the same;

[0054] Step N2. Then, through: ;

[0055] Calculate the improved contact area increase ratio c.

[0056] Step N3. Subsequently, through: ;

[0057] Calculate the improved voltage drop reduction ratio γ.

[0058] In the formula, U0 is the initial voltage drop, and U1 is the improved voltage drop.

[0059] Step N4. Compare the voltage drop reduction ratio γ with the preset voltage drop reduction threshold γa:

[0060] When γ > γa, it indicates that the improved contact area after the contact surface optimization treatment is effective. At the same time, calculate the proportional adjustment coefficient B between the contact area increase ratio and the voltage drop reduction ratio through B = c / γ.

[0061] As a further solution of the present invention: The calculation method of the adjusted contact area is as follows:

[0062] Obtain the voltage drop reduction ratio difference by subtracting the improved voltage drop reduction ratio from the voltage drop target reduction threshold.

[0063] Subsequently, obtain the secondary contact area increase ratio by dividing the current improved contact area by the proportional adjustment coefficient B.

[0064] Then, through: ;

[0065] Calculate the corresponding adjusted contact area SK of the iron or carbon block.

[0066] As a further solution of the present invention: The increasing treatment method is: Process the contact surface of the iron or carbon block into a serrated shape; The specific serrated processing method is as follows:

[0067] Step H1. First, through: , calculate the adjusted difference SC0 of the contact area corresponding to the iron or carbon block.

[0068] Step H2. On the iron or carbon block, select multiple uniformly distributed regions with the same specified area size as the serrated processing regions.

[0069] Step H3. Subsequently, perform groove cutting and grinding on the processing regions, and then calculate the area of the grooves corresponding to the processing regions.

[0070] Step H4. Then, select the processing regions, and subtract the area of the grooves corresponding to the processing regions from the specified area of the processing regions before groove cutting to obtain the area difference of the processing regions.

[0071] Step H5. Then, sum up the area differences of all machining areas to obtain the increased area of the serrated contact surface.

[0072] Step H6. Finally, compare the increased area of the serrated contact surface with the adjusted difference of the contact area:

[0073] When the increased area of the serrated contact surface is greater than or equal to the adjusted difference of the contact area, it is determined that the machining of the corresponding serrated contact surface is completed.

[0074] When the increased area of the serrated contact surface is less than the adjusted difference of the contact area, continue to cut and polish the grooves in each machining area until the increased area of the serrated contact surface is greater than or equal to the adjusted difference of the contact area.

[0075] Among them, the grooves in each machining area are finely cut in batches according to the adjusted difference of the contact area.

[0076] A control system for an anode carbon block production line, which is used to execute a control method for an anode carbon block production line. The system includes:

[0077] A contact area measurement module, which is used to measure the initial contact area and the initial voltage drop between iron and the carbon block in the initial contact state.

[0078] A voltage drop detection module, which is used to apply current and measure the initial voltage drop between iron and the carbon block in the initial contact state.

[0079] A surface treatment module, which is used to control mechanical grinding or polishing operations.

[0080] A conductive material filling module, which is used to automatically fill graphite powder.

[0081] A dynamic adjustment module, which is used to calculate and execute contact area adjustment.

[0082] As a further solution of the present invention: The system further includes:

[0083] A roughness measuring instrument, which is used to monitor the roughness change of the contact surface in real time.

[0084] As a further solution of the present invention: The dynamic adjustment module integrates a serrated machining device, and the groove cutting is realized through a numerical control machine tool.

[0085] The beneficial effects of the present invention:

[0086] Optimizing Contact Performance: By means of mechanical grinding or polishing operations on the contact surface between iron and carbon blocks, and optimization measures such as filling highly conductive materials (such as graphite powder), the contact area between the two has been effectively increased, and the voltage drop has been reduced. Through the optimization verification steps, the improvement ratio of the contact area and the reduction ratio of the voltage drop can be accurately calculated. When the reduction ratio of the voltage drop meets the pre-set threshold, it indicates that the optimized contact area is effective, thereby improving the conductivity in the anode carbon block production line and reducing power consumption.

[0087] Precise Measurement and Calculation: In terms of measuring the initial contact area and voltage drop, the conductive coating method is used to measure the initial contact area, and the initial voltage drop is measured by applying a constant current and a voltage measuring instrument. The method is scientific and accurate; when calculating the theoretical maximum contact area, reasonable calculation methods are given respectively for different contact situations (plane contact and non-plane contact); for the measurement of the effective contact area of graphite powder, it is accurately estimated by measuring the thickness and area of the filling area, combined with the bulk density and proportional coefficient, etc., ensuring the accuracy of the measurement and calculation of each parameter, and providing a reliable basis for subsequent optimization and adjustment.

[0088] Dynamic Adjustment and Adaptability: It has a dynamic adjustment mechanism for the contact area. By comparing the reduction ratio of the voltage drop with the pre-set target reduction threshold, it can accurately determine whether the current optimized contact area has achieved the expected effect. When the expected effect is not achieved, the adjusted contact area corresponding to iron or carbon blocks can be determined according to the calculation, and accordingly, it can be increased, enabling the system to adaptively optimize the contact area according to the actual situation to meet the voltage drop target requirements and ensure the stable operation of the anode carbon block production line.

[0089] Scientific and Reasonable Processing of the Contact Surface: The method of increasing the contact surface (processing the contact surface of iron or carbon blocks into a serrated shape) is scientific and reasonable. Through a series of steps such as accurately calculating the adjustment difference of the contact area, selecting a suitable processing area, cutting grooves and grinding the processing area, and calculating the area difference of the area, the processing of the serrated contact surface is gradually realized, ensuring that the increased contact area can meet the adjustment requirements and further improving the contact performance between iron and carbon blocks.

[0090] Strong Operability: In each step of the entire control system and method, such as measurement, calculation, processing, etc., detailed operation methods and specific calculation formulas are given, and clear methods for obtaining each parameter are also provided (such as the selection of measurement tools, the determination of bulk density, etc.), making the system and method highly operable and facilitating implementation and application in the actual anode carbon block production line. Description of the Drawings

[0091] The present invention will be further described below in conjunction with the drawings.

[0092] Figure 1It is a schematic flow chart of a control method for an anode carbon block production line according to the present invention.

[0093] Figure 2 It is a system block diagram of a control system for an anode carbon block production line according to the present invention.

[0094] Figure 3 It is a cutting schematic diagram of a zigzag contact surface in a control system and method for an anode carbon block production line according to the present invention. Detailed implementation manners

[0095] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without making creative efforts shall fall within the protection scope of the present invention.

[0096] As the first embodiment of the present invention:

[0097] Please refer to Figure 1 and Figure 3 As shown, the present invention is a control method for an anode carbon block production line, including the following steps:

[0098] Step 1: Measurement of initial contact area and voltage drop:

[0099] Under the initial contact state of iron and carbon block, measure the initial contact area and initial voltage drop between the two;

[0100] Among them, the measurement method of the initial contact area is as follows:

[0101] Adopt the conductive coating method, coat the conductive material on the contact surface, and calculate the contact area by measuring the conductive area;

[0102] The measurement method of the initial voltage drop is as follows:

[0103] Apply a constant current between iron and carbon block, then pass through a voltage measuring instrument to measure the voltage difference at both ends, and record it as the initial voltage drop;

[0104] Step 2: Calculation of maximum contact area:

[0105] The theoretical maximum contact area between iron and carbon block is determined by the geometric shapes of the two;

[0106] For planar contact, the theoretical maximum contact area is the surface area of the smaller one of the two;

[0107] Illustrate with examples:

[0108] For example, if the contact plane area of the iron electrode is 20 cm 2, the contact plane area of the carbon block is 15 cm 2 , then the theoretical maximum contact area is 15 cm 2 ;

[0109] For non-planar contact, it is calculated by the following method:

[0110] In this embodiment, non-planar contact refers to an arc surface or a rough surface;

[0111] If one of the iron surface and the carbon block is planar and the other is an arc surface, the theoretical maximum contact area is the area of the tangent contact region between the arc surface and the plane;

[0112] Its calculation formula is: S max = 2πrh;

[0113] In the formula, S max is the theoretical maximum contact area between the iron surface and the carbon block, r is the radius of the arc surface, and h is the contact height;

[0114] For example:

[0115] If the iron surface is planar and the carbon block surface is arc-shaped, and at the same time assume that the radius of the arc surface of the carbon block r = 5 cm and the contact height h = 2 cm, then S max = 2π×5×2 = 20π≈62.8 cm 2 ;

[0116] Step Three: Contact surface optimization:

[0117] Adopt the following method to increase the actual contact area between iron and carbon block:

[0118] Step R1: Surface flattening treatment:

[0119] Perform mechanical grinding or polishing operations on the contact surface of iron or carbon block;

[0120] In this embodiment, mechanical grinding or polishing can reduce the surface roughness and make the contact between iron or carbon block closer;

[0121] Before performing mechanical grinding or polishing operations, measure the initial roughness of the contact surface of iron or carbon block with a roughness measuring instrument and record it as R0;

[0122] After performing mechanical grinding or polishing operations, measure the processed roughness of the contact surface of iron or carbon block with a roughness measuring instrument and mark it as R1;

[0123] Then through: , calculate the theoretical maximum contact area S1 after flattening treatment max ;

[0124] Wherein, β is a pre-set material adaptation coefficient. In this embodiment, the value of β for iron and carbon materials ranges from 0.6 to 0.8;

[0125] Step R2: Conductive material filling treatment:

[0126] Fill a highly conductive material between the iron and the carbon block;

[0127] In this embodiment, graphite powder is selected as the highly conductive material;

[0128] Then, through: , calculate the theoretical maximum contact area S2 after the conductive material filling treatment max ;

[0129] Wherein, AS is the effective contact area of the highly conductive material;

[0130] Step Four: Optimization verification:

[0131] Step N1: Measure the optimized contact area and optimized voltage drop after being processed by the above optimization method in the same way as measuring the initial contact area and voltage drop in Step One;

[0132] The measurement method of the optimized contact area is the same as that of the initial contact area;

[0133] The measurement method of the optimized voltage drop is the same as that of the initial voltage drop;

[0134] Step N2: Then, through: ;

[0135] Calculate the improvement ratio c of the contact area after optimization;

[0136] Step N3: Then, through: ;

[0137] Calculate the reduction ratio γ of the voltage drop after optimization;

[0138] Wherein, U0 is the initial voltage drop and U1 is the optimized voltage drop;

[0139] Step N4: Compare the voltage drop reduction ratio γ with the pre-set voltage drop reduction threshold γa:

[0140] When γ > γa, it indicates that the optimized contact area after the contact surface optimization treatment is effective. At the same time, calculate the proportional adjustment coefficient B between the contact area improvement ratio and the voltage drop reduction ratio through B = c / γ;

[0141] Step Five: Dynamic adjustment of the contact area:

[0142] Obtain the pre-set target voltage drop reduction threshold γm, and then compare the voltage drop reduction ratio γ with it:

[0143] When γ ≥ γm, it is determined that the current optimized contact area after the optimization treatment of the contact surface reaches the expected effect;

[0144] When γ < γm, it is determined that the current optimized contact area after the optimization treatment of the contact surface does not reach the expected effect. Then, the contact area corresponding to the adjusted iron or carbon block is determined. Finally, the contact surface between the iron and the carbon block is increased according to the adjusted contact area;

[0145] The calculation method of the adjusted contact area is as follows:

[0146] By subtracting the optimized voltage drop reduction ratio from the voltage drop target reduction threshold, the voltage drop reduction ratio difference is obtained;

[0147] Then, by dividing the current optimized contact area by the proportional adjustment coefficient B, the secondary contact area increase ratio is obtained;

[0148] Then, through: ;

[0149] The contact area SK corresponding to the adjusted iron or carbon block is calculated;

[0150] The increasing treatment method is: processing the contact surface of the iron or carbon block into a serrated shape, as Figure 3 shown;

[0151] In the first embodiment, by measuring the initial contact area and voltage drop between the iron and the carbon block, and combining with the calculation of the theoretical maximum contact area, two methods for optimizing the contact surface, namely surface flattening treatment and conductive material filling treatment, are proposed. By comparing the contact area and voltage drop before and after optimization, calculating the increase ratio and reduction ratio, judging the optimization effect and obtaining the proportional adjustment coefficient. When the optimized voltage drop reduction ratio is greater than the preset threshold, it indicates that the optimization is effective, and the contact area can be dynamically adjusted according to the proportional adjustment coefficient and the target reduction threshold to achieve the expected effect, effectively improving the control and optimization ability of the contact performance between the iron and the carbon block in the anode carbon block production line, and laying a foundation for improving production efficiency and product quality.

[0152] As the second embodiment of the present invention:

[0153] Please refer to Figure 1 and Figure 3 shown. As the second embodiment of the present invention, in the specific implementation of the present application, compared with the first embodiment, the technical solution of this embodiment is only different from that of the first embodiment in that in this embodiment, it is also proposed that the effective contact area of the graphite powder corresponding to the filling material is obtained by measuring the thickness and area of the filling area and combining with the parameters corresponding to the bulk density of the graphite powder;

[0154] The specific method is as follows:

[0155] Measuring the thickness of the filled area:

[0156] Use high-precision thickness measuring instruments such as micrometers, laser thickness gauges, etc.;

[0157] In the area filled with graphite powder, select multiple measurement points evenly distributed in the filled area for thickness measurement;

[0158] Illustrative example:

[0159] For example, for a rectangular filled area, measure the thickness at the four corners and the center position respectively to obtain the measured thickness values h1, h2, h3, h4, h5 of each measurement point;

[0160] Then through h p =(h1 + h2 + h3 + h4 + h5) / 5, calculate the average thickness h p ;

[0161] Measuring the area of the filled area:

[0162] If the filled area is a regular geometric shape, such as a rectangle, use a ruler tool to measure its length a and width b, and according to the rectangle area formula S t =a×b, calculate the filled area S t ;

[0163] If it is a circle, use a caliper to measure its diameter d, according to the circle area formula S t =π(d / 2) 2 to calculate the filled area S t ;

[0164] Determine the bulk density of graphite powder: Determine the bulk density ρ of graphite powder by referring to relevant materials or conducting self-experiments;

[0165] When conducting self-experiment, pour a certain mass m of graphite powder into a container with a known volume V, gently vibrate to make the graphite powder densely packed, and then according to the density calculation formula ρ = m / V, calculate the bulk density of graphite powder;

[0166] Estimate the effective contact area: Assume that the graphite powder is evenly distributed in the filled area, according to the volume formula V = S t ×h p to calculate the volume filled with graphite powder;

[0167] Combined with the bulk density, estimate the mass of graphite powder m = ρ×S t ×h p ;

[0168] The proportionality coefficient e between the effective contact area and the mass of graphite powder is determined through experiments, specifically as follows: Measure the effective contact area of graphite powder with a specified mass under standard contact conditions to obtain this proportional relationship;

[0169] Then the effective contact area AS = e×m = e×ρ×S t ×h p ;

[0170] Based on Example 1, Example 2 proposes a detailed method for calculating the effective contact area of graphite powder during the filling treatment of conductive materials. By measuring the thickness of the filling area (measuring at multiple evenly distributed points and taking the average value), measuring the area of the filling area (calculating using corresponding formulas according to different geometric shapes), and determining the bulk density of graphite powder (referring to data or measuring by oneself), the effective contact area is estimated. This method makes the calculation of the effective contact area of graphite powder more accurate during the filling treatment of conductive materials, further improving the accuracy of optimizing the contact surface calculation, providing strong support for more precisely optimizing the contact performance between iron and carbon blocks, and contributing to improving the scientificity and reliability of the control system and method for the anode carbon block production line.

[0171] As Example 3 of the present invention:

[0172] Please refer to Figure 1 and Figure 3 As shown, as Example 3 of the present invention, when the present application is specifically implemented, compared with Example 1 and Example 2, the technical solution of this example lies in combining the solutions of the above Example 1 and Example 2. The difference between the technical solution of this example and Example 1 and Example 2 is only that this example also proposes a specific way to increase the treatment, and the way is referred to as a zigzag processing method, specifically as follows:

[0173] Step H1: First, through: , calculate the adjustment difference SC0 of the corresponding contact area of iron or carbon block;

[0174] Step H2: On the iron or carbon block, select multiple evenly distributed areas with the same specified area size as the zigzag processing areas;

[0175] Step H3: Then perform groove cutting and grinding on the processing areas, and then calculate the area of the corresponding grooves in the processing areas;

[0176] Step H4: Next, select the processing areas, and subtract the area of the corresponding grooves in the processing areas from the specified area of the processing areas before groove cutting to obtain the area difference of the processing areas;

[0177] Step H5: Then add up the area differences of all processing areas to obtain the increased area of the zigzag contact surface;

[0178] Step H6. Finally, compare the increased area of the serrated contact surface with the adjusted difference in contact area:

[0179] If the increased area of the serrated contact surface is greater than or equal to the adjusted difference in contact area, it is determined that the current corresponding serrated contact surface machining is completed;

[0180] If the increased area of the serrated contact surface is less than the adjusted difference in contact area, continue to cut and polish the grooves in each machining area until the increased area of the serrated contact surface is greater than or equal to the adjusted difference in contact area;

[0181] In this embodiment, the grooves in each machining area are finely cut in batches according to the adjusted difference in contact area;

[0182] Based on Embodiment 1 and Embodiment 2, Embodiment 3 clarifies the specific method of serrated machining in the process of increasing the contact area. By calculating the adjusted difference in the contact area of the iron or carbon block, a uniformly distributed area with a specified area is selected as the machining area, and grooves are cut, polished and the groove area is calculated to obtain the area difference of the region. Then, by comparing the increased area of the serrated contact surface with the adjusted difference, it is determined whether the machining is completed. This detailed machining method makes the process of increasing the contact area more operable and controllable, can more effectively achieve the precise adjustment of the contact area, improves the process level of the contact area adjustment link in the anode carbon block production line, and ensures the achievement of the optimization effect.

[0183] As Embodiment 4 of the present invention:

[0184] Please refer to Figure 1 and Figure 3 As shown, in Embodiment 4 of the present invention, in the specific implementation of the present application, compared with Embodiment 1, Embodiment 2 and Embodiment 3, the technical solution of this embodiment is to combine and implement the solutions of the above Embodiment 1, Embodiment 2 and Embodiment 3. At the same time, in this embodiment, any one of Step R1, surface flattening treatment and Step R2, conductive material filling treatment is also used to calculate the maximum contact area;

[0185] When only surface flattening treatment is adopted, Step R2 is not continued;

[0186] When only conductive material filling treatment is adopted, then .

[0187] Embodiment 4 combines the solutions of Embodiment 1, 2 and 3, comprehensively integrating technical points such as measuring initial parameters, optimizing the contact surface method, accurately calculating the effective contact area of graphite powder, and detailed serrated machining methods.

[0188] By allowing the calculation of the maximum contact area in only one of the surface planarization treatment or conductive material filling treatment methods, the adaptability and operability of the system are greatly enhanced. If only the surface planarization treatment is adopted, the system can focus on improving the contact performance through mechanical grinding or polishing, avoiding unnecessary conductive material filling steps, simplifying the operation process, and improving work efficiency; if only the conductive material filling treatment is adopted, it can give full play to the advantages of highly conductive materials for specific production requirements and precisely optimize the contact effect. This flexible selection mechanism enables the entire system to better adapt to different production scenarios and process requirements, comprehensively improving the technical level of the anode carbon block production line, effectively ensuring the stability and efficiency of the production process as well as the reliability of product quality, and bringing a more valuable innovative solution to the anode carbon block production field;

[0189] This comprehensive combined implementation method optimizes the contact performance between iron and carbon blocks in the anode carbon block production line in all aspects, from the measurement of contact performance parameters, the implementation of optimization methods to the control of processing details, maximizing the integrity, scientificity, and effectiveness of the entire control system and method, providing a more complete and efficient technical solution for anode carbon block production, and effectively ensuring the stability of the production process and the reliability of product quality.

[0190] The present invention also provides a control system for an anode carbon block production line, which is used to execute a control method for an anode carbon block production line. The system includes:

[0191] A contact area measurement module, which is used to measure the initial contact area and the initial voltage drop between iron and carbon blocks in the initial contact state;

[0192] A voltage drop detection module, which is used to apply current and measure the initial voltage drop between iron and carbon blocks in the initial contact state;

[0193] A surface treatment module, which is used to control mechanical grinding or polishing operations;

[0194] A conductive material filling module, which is used to automatically fill graphite powder;

[0195] A dynamic adjustment module, which is used to calculate and execute contact area adjustment. The dynamic adjustment module integrates a zigzag machining device and realizes groove cutting through a numerical control machine tool;

[0196] A roughness measuring instrument, which is used to monitor the roughness change of the contact surface in real time.

[0197] The above formulas are all dimensionless and take their numerical values for calculation. The formulas are obtained by collecting a large amount of data and performing software simulation to get a formula closest to the real situation. The preset parameters and threshold selection in the formulas are set by those skilled in the art according to the actual situation.

[0198] As described above, it is only the specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present application can easily think of changes or substitutions, which should all be covered within the protection scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.

Claims

1. A control method for an anode carbon block production line, characterized in that, Including: Initial contact area and voltage drop measurement: Measure the initial contact area and the initial voltage drop between iron and carbon blocks in the initial contact state; Calculation of maximum contact area: For planar contact, the theoretical maximum contact area is the surface area of the smaller of the two; for non-planar contact, calculate through the contact area of the tangent contact region between the arc surface and the plane; Optimization of the contact surface: Perform mechanical grinding or polishing operations on the contact surfaces of iron or carbon blocks, and fill high-conductivity materials between iron and carbon blocks; Optimization verification: Measure the optimized contact area and voltage drop, then calculate the contact area increase ratio and voltage drop decrease ratio. When the voltage drop decrease ratio is greater than the preset voltage drop decrease threshold, calculate the ratio adjustment coefficient between the contact area increase ratio and the voltage drop decrease ratio; Dynamic adjustment of the contact area: Compare the voltage drop decrease ratio with the preset target voltage drop decrease threshold. According to the comparison result, determine the corresponding adjusted contact area of iron or carbon blocks, and finally increase the contact surface between iron and carbon blocks according to the adjusted contact area.

2. The control method for an anode carbon block production line according to claim 1, wherein Among them, The measurement method of the initial contact area is as follows: Adopt the conductive coating method, coat the conductive material on the contact surface, and calculate the contact area by measuring the conductive area; The measurement method of the initial voltage drop is as follows: Apply a constant current between iron and carbon blocks, then measure the voltage difference at both ends through a voltage measuring instrument and record it as the initial voltage drop.

3. A control method for an anode carbon block production line according to claim 2, characterized in that The calculation formula for the area of the tangential contact region is: S max = 2πrh; where S max is the theoretical maximum contact area between the iron surface and the carbon block, r is the radius of the arc surface, and h is the contact height.

4. The control method for an anode carbon block production line according to claim 3, wherein In the contact surface optimization step: Before performing mechanical grinding or polishing operations, measure the initial roughness of the contact surfaces of iron or carbon blocks with a roughness measuring instrument and record it as R0; After performing mechanical grinding or polishing operations, measure the processed roughness of the contact surfaces of iron or carbon blocks with a roughness measuring instrument and mark it as R1; Followed by: Calculating the theoretical maximum contact area S1 after flattening max ; In the formula, β is the preset material adaptation coefficient; Then, through: S2 max = S1 max + AS, calculate the theoretical maximum contact area S2 after the conductive material filling process max ; In the formula, AS is the effective contact area of the high-conductivity material.

5. A control method for an anode carbon block production line according to claim 4, characterized in that, Among them, The high-conductivity material is selected as graphite powder; the effective contact area of graphite powder is obtained by measuring the thickness and area of the filling area and combining the parameters corresponding to the bulk density of graphite powder. The specific method is as follows: Measure the thickness of the filling area: Use a thickness measuring instrument to measure the thickness at multiple measurement points evenly distributed in the area filled with graphite powder in the area filled with graphite powder; Measuring the area of the filled region: If the filled region is a rectangle, use a ruler tool to measure its length and width, and calculate the area S of the filled region according to the rectangle area formula t ; If the filled area is circular, use a caliper to measure its diameter, and calculate the filled area S according to the formula for the area of a circle t ; Determine the bulk density of graphite powder: Determine the bulk density ρ of graphite powder by referring to relevant materials or through self-experiment; Estimate the effective contact area: Assume that the graphite powder is evenly distributed in the filling area. According to the volume formula V = S t ×h p , calculate the volume filled with graphite powder; Combined with the bulk density, the mass m of the graphite powder is estimated as m = ρ × S t × h p ; Determine the proportional coefficient e between the effective contact area and the mass of graphite powder through experiments; Then the effective contact area AS = e × m = e × ρ × S t × h p .

6. The control method for an anode carbon block production line according to claim 4, wherein, The specific method of optimization verification is as follows: Step N1, Measure the optimized contact area and optimized voltage drop in the same way as the initial contact area and voltage drop measurement; The measurement methods of the optimized contact area and the initial contact area are the same; The measurement methods of the optimized voltage drop and the initial voltage drop are the same; Step N2. Then, through: Calculate the contact area increase ratio c after optimization; Step N3, then through: Calculate the voltage drop decrease ratio γ after optimization; In the formula, U0 is the initial voltage drop, and U1 is the optimized voltage drop; Step N4, Compare the voltage drop decrease ratio γ with the preset voltage drop decrease threshold γa: When γ > γa, it indicates that the optimized contact area after the contact surface optimization treatment is effective. At the same time, the proportional adjustment coefficient B between the contact area increase ratio and the voltage drop reduction ratio is calculated through B = c / γ.

7. A control method for an anode carbon block production line according to claim 6, characterized in that, The calculation method of the adjusted contact area is as follows: The voltage drop reduction ratio difference is obtained by subtracting the optimized voltage drop reduction ratio from the voltage drop target reduction threshold; Then, the secondary contact area increase ratio is obtained by dividing the current optimized contact area by the proportional adjustment coefficient B; Then, through: SK = c × S2 max + S2 max ; The adjusted contact area SK corresponding to the iron or carbon block is calculated.

8. The control method of an anode carbon block production line according to claim 7, characterized in that, The comparison method in the dynamic adjustment of the contact area is as follows: When γ ≥ γm, it is determined that the current optimized contact area after the contact surface optimization treatment reaches the expected effect and no increase treatment is performed; When γ < γm, it is determined that the current optimized contact area after the contact surface optimization treatment does not reach the expected effect, and then increase treatment is performed; γ is the voltage drop reduction ratio, and γm is the preset voltage drop target reduction threshold.

9. A control method for an anode carbon block production line according to claim 8, characterized in that The increase treatment method is: processing the contact surface of the iron or carbon block into a serrated shape; the specific serrated processing method is as follows: Step H1. First, calculate the adjustment difference SC0 of the contact area corresponding to the iron or carbon block through: SC0 = SK - S2 max , where SC0 is the adjustment difference of the contact area corresponding to the iron or carbon block Step H2: On the iron or carbon block, select multiple uniformly distributed areas with the same specified area size as the serrated processing areas; Step H3: Then, perform groove cutting and grinding on the processing areas, and then calculate the area of the grooves corresponding to the processing areas; Step H4: Next, select the processing areas, and subtract the area of the grooves corresponding to the processing areas from the specified area of the processing areas before groove cutting to obtain the area difference of the processing areas; Step H5: Then, add up the area differences of all the processing areas to obtain the increased area of the serrated contact surface; Step H6: Finally, compare the increased area of the serrated contact surface with the adjustment difference of the contact area: When the increased area of the serrated contact surface is greater than or equal to the adjustment difference of the contact area, it is determined that the current corresponding serrated contact surface processing is completed; When the increased area of the serrated contact surface is less than the adjustment difference of the contact area, continue to cut and grind the grooves of each processing area until the increased area of the serrated contact surface is greater than or equal to the adjustment difference of the contact area.

10. A control system for an anode carbon block production line, which is used to implement the control method of an anode carbon block production line according to any one of claims 1-9, characterized in that, The system includes: A contact area measurement module, used to measure the initial contact area and the initial voltage drop between the iron and the carbon block in the initial contact state; A voltage drop detection module, used to apply current and measure the initial voltage drop between the iron and the carbon block in the initial contact state; A surface treatment module, used to control mechanical grinding or polishing operations; A conductive material filling module, used to automatically fill graphite powder; A dynamic adjustment module, used to calculate and perform contact area adjustment.

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